Conveyor apparatus and method

ABSTRACT

A conveyor apparatus and method for a continuous haulage system and continuous conveyor belt are disclosed for carrying coal or ore. A middle roller and side sliders are connected with substantially flexible linkages on a roller-slider support piece supporting the continuous conveyor belt. Three apertures are positioned on the holding frame to adjust and control the tracking angle at which the support piece receives the continuous conveyor belt. In one aspect, the holding frame is provided by a plurality of floor-supported frame members held in position by belt tension, the holding frame being capable of rapid and efficient extendable, retractable construction in the mine, and wherein substantially flexible connecting linkages are positioned to connect the middle roller and the side slider and to connect the side slider to a holding frame for holding the roller-slider support piece. Rails connecting and hold adjacent frame members in position by press-fit attachment of the rails to the frame members. The rails preferably are quickly rotatable to change the top wearing surface.

This patent application is a continuation-in-part of prior patent application U.S. Ser. No. 08/125,598 filed Sep. 23, 1993, now U.S. Pat. No. 5,353,920; prior patent application U.S. Ser. No. 08/314,881 filed Sep. 29, 1994, now U.S. Pat. No. 5,590,757; and prior, patent application U.S. Ser. No. 08/460,236 filed Jun. 2, 1995, now U.S. Pat. No. 5,645,158.

BACKGROUND OF THE INVENTION

1. Technical Field

This invention relates to conveyor apparatus and method for use in mining operations. In one aspect, this invention relates to mining conveyor apparatus and method for performing continuous haulage in a mine.

2. Background

Mining operations today use conveyor apparatus extensively to remove material, e.g., such as coal or ore, from the mine. The conveyor apparatus improves productivity over those methods which do not have “continuous” means for removing the mined material from the mine face.

U.S. Pat. No. 4,031,997, issued to Nelson, discloses a mobile cascade conveyor system, but nevertheless presents a background of the invention describing parallel room mining with intermittent/discontinuous or continuous methods for carrying coal from the continuous miner.

Continuous miner machines work at removing the mined material, e.g., ore or coal, from the mine face and thereby extend into the mine and away from the conveyor or other means for removing the material produced by the continuous miner. After the continuous miner extends so far, the miner must be retracted away from the mine face to install or construct roof supports. Accordingly, the mined material removal means, e.g., the conveyor apparatus, must be capable of extension and retraction in conjunction with movement of the continuous miner.

Conveyor apparatus available commercially today can be viewed as severely limited with respect to its flexibility and ease of operation in providing the extension and retractability for following the continuous miner. A new apparatus and method are needed to provide removal of large amounts of mined material for continuous haulage conveyance out of the mine.

INTRODUCTION TO THE INVENTION

In the mining of coal today, mining companies are finding the need to provide for the removal of larger and larger volumes and weights of mined material by continuous haulage conveyance out of the mine. Conveyor apparatus and method are needed to receive and convey heavier loads, and to operate in the mine environment which typically subjects the conveyor apparatus to harsh and hostile chemical attack with small particles together with damaging physical forces placed on the conveyor structure by the larger volumes and weights of coal to be conveyed.

In the mining of coal, particularly but not limited to coal strip mines, many coal seams are exposed and/or identified which have a low vertical seam height. By low vertical seam height is meant less than standing room. The low coal seam vertical height makes it extremely difficult to impossible to recover the coal by conventional deep mining equipment and techniques. The low coal is left behind when the cover over the seam is too high to mine the coal by strip mining techniques. Moreover, since the vertical height of these coal seams is so low, it is extremely difficult, if not impossible, to mine the low coal with people in the shaft.

One technique which has developed to mine low coal is with the use of continuous mining equipment. A continuous miner works at the face of the low seam vertical height coal and separates the coal from the face of the mine. The coal produced from the continuous miner is passed preferably to a “continuous haulage” system for removal from the mine face, typically by passing through an extensible conveyor to a mainline conveyor for removal from the mine. By continuous haulage is meant the continuous transportation of the material mined from a continuous miner, from other mining machines, or from a production area to a main conveyor belt or belts leading to the surface or to a main terminal area where the mined material is processed.

Coal produced from the mine face in larger vertical height mines also is conveyed today by a continuous haulage system for removal from the mine.

U.S. Pat. No. 2,850,146, issued to Madeira, (hereinafter “Madeira”) discloses a structure and technique considered to be the beginnings of low belt structure as it is known today. U.S. Pat. No. 2,850,146 discloses a portable conveyor for use in a coal mine represented to be simple in the setting up thereof, and also by ready portability in the mine or the like. An endless conveyor is provided having a pair of cables suspended as catenaries on spaced roof jacks. The endless conveyor belt is represented to be readily and easily disassembled and moved from one location to another location where the conveyor is easily reassembled. When positioned at the new location, it is extensible and retractable with a minimum amount of effort.

U.S. Pat. No. 2,850,146 discloses structure which is cable mounted, supported by roof jacks. A drawback of the cable-mounted system involves problems attributable to failure of suspension of the conveyor line when even just one roof jack loses its support. Loss of roof support is a problem which can and does occur, resulting in the cable structure losing its support.

The U.S. Pat. No. 2,850,146 patent utilizes rollers, not sliders, and the structure disclosed in U.S. Pat. No. 2,850,146 is intended to be readily installed, but the actual structure design is deficient in the length of time actually needed to install it. The apparatus and methods disclosed in U.S. Pat. No. 2,850,146 are not designed to run continuous haulage because the Madeira conveyor does not form a track needed for the mobile bridge units extending from and attached to the continuous mining machine to tram or travel in order to form the continuous haulage system.

In underground mining, and particularly in but not limited to underground mining wherein the vertical work space affords less than standing room, physical tasks are made more difficult by the confined spaces and constraints imposed by the underground mine. Although the apparatus and method of the present invention are not intended to be limited by particular dimensions in a mine, physical movements and activity are made significantly more demanding in low seam mining, e.g., less than 48 inches in vertical height.

When conveyor apparatus is used in continuous haulage today to remove material from the mine, and when the conveyor apparatus is called upon to extend and retract in conjunction with the continuous miner, the conveyor must be repeatedly constructed and later broken down in the confining spaces and constraints within the mine. Conventional conveyor apparatus can be viewed as severely lacking in the areas of facilitating extension or retraction while accommodating the difficult physical activities found in the confining spaces or constraints in the underground mine. Novel apparatus and method are needed to facilitate rapid and flexible extension and retraction of the conveyor in the underground mine.

Conventional conveyor belts typically use idler rollers and/or roller bearings for carrying the main belt for hauling material on the endless conveyor belt. The idler rollers and/or roller bearings have difficult duty in the hostile environment of the mine. This hostile environment is attributable to water, corrosion, dust, or other hostile agents found in the mine. When the idler rollers or roller bearings need to be replaced, the load bearing surface typically undergoes a grinding operation by the belt as it passes. When the idler roller or roller bearing is ground to a sharp surface, the conveyor must be taken down to replace the belt.

The difficult duty of idler rollers or rollers containing roller bearings is made more acute with low vertical height mining because the rollers must be made of smaller diameter. The smaller diameter rollers must travel faster because of the higher number of revolutions per unit time. Accordingly, novel conveyor apparatus and method are needed to eliminate problems attributable to conventional idler rollers and other rollers using roller bearings.

It has been proposed to use slides as substitute apparatus for idler rollers. Slides are available commercially, made typically of stainless steel. However, stainless steel has a high coefficient of friction, e.g., such as on the order of 0.550-0.7, and the stainless steel wears out because of a higher coefficient of friction and the attendant abrasion that goes with the higher coefficient of friction. When the stainless steel slider wears out, or in anticipation of the slider wearing out as part of a preventative maintenance program, the stainless steel slider must be periodically disassembled and taken out of the mine to put in a new stainless slider. The stainless steel slider is taken out of the mine to weld in place the metal slider into the slider frame. The rebuilt stainless steel slider then is taken back into the mine and retrofitted into the conveyor.

Accordingly, novel conveyor apparatus and method are needed to overcome the drawbacks attributable to materials such as stainless steel having limited abrasion resistance and difficult fabrication.

U.S. Pat. No. 4,789,056, issued to Bourbeau, discloses a slider bed conveyor apparatus and method also incorporating idler rollers. The patent discloses that when a load such as impact loads are placed on the conveyor belt, the slider bed supports the conveyor belt at the point where the material is loaded. This action in receiving the impact loads resists sagging and stretching of the conveyor belt and also reduces wear on the idler rollers. The idler rollers are mounted on a shaft and are adapted to be adjustable vertically depending on the load requirements. The conveyor belt system is modular and of unitary structure, and several modules can be joined to form a conveyor belt system of any designed length.

U.S. Pat. Nos. 5,038,924 and 5,103,967, issued to Stoll, disclose an impact saddle for use in place of a conventional impact roller assembly for supporting a bulk material conveyor at an impact zone. The assembly includes a support frame adapted to be positioned in transverse relation to the length of the belt. The support frame forms a pair of side-by-side T-shaped supports which extend in parallel relation transversely of the belt. A plurality of polymeric low friction segments, such as high molecular weight polyethylene, are formed with lower T-shaped slots which are adapted to receive the T-shaped supports for threading onto the support frame. The segments have upper surfaces which collectively form a support for a section of the conveyor belt in the impact zone.

U.S. Pat. No. 4,215,776, issued to Esler, (hereinafter “Esler”) discloses a belt conveyor idler having a ridged U-shaped channel fixedly mounted on a pair of spaced supports. A rigid strip of a low-friction material, such as high molecular weight polyethylene, is fixedly mounted within the channel and extends transversely across the path of the conveyor belt for slidably supporting the conveyor belt. The channel and strip of low-friction material each have a complimentary catenary configuration for the load-bearing troughing run of the conveyor belt and a straight horizontal configuration for the return run of the belt.

Conveyors such as the Esler conveyor will not work with continuous haulage systems. By continuous haulage is meant the uninterrupted transportation of material from a continuous miner unit to the mine transportation system by several units of haulage equipment and an associated continuous and advancing conveyor system.

The Esler conveyor also will not provide or facilitate the extension or retraction such that the conveyor can be put together and taken apart quickly and easily, particularly with confining spaces and constraints in an underground mine. Esler discloses belt conveyor idlers bolted onto end posts 5 bolted onto support channels 3 bolted onto suspension bracket 34.

U. S. Pat. No. 4,736,835, issued to Hinkle, (hereinafter “Hinkle”) discloses a conveyor support frame incorporating a top bar “receiver” into which a top bar is inserted and rotated for the purpose of moving rigid locking elements of the top bars into a complex secure engagement with the receiver. Although Hinkle discloses a purpose to provide a quick release connection joint between support stands, the requirements in Hinkle to line up, turn, and lock the interlocking mechanism and receiver (and conversely to unlock, turn, and withdraw locking lugs 27 and 28 from jaw plate 20 for removal) are found to be difficult to operate in the confining spaces and in the muck and mire found typically in an underground mine. Further, the Hinkle locking lugs 27 and 28 of longitudinal bars 11 are locked into the receivers 18 and jaw plates 20 in such a way that they can only be inserted in one specific configuration, i.e., the top surfaces of the rails are not rotatably interchangeable.

Accordingly, new mining conveyor apparatus and method are needed to overcome the deficiencies found in conventional systems.

It is an object of the present invention to provide novel mining conveyor apparatus and method for a continuous haulage system.

It is an object of the present invention to provide novel mining conveyor apparatus and method to provide for the removal of large volumes and weights of mined material by continuous haulage conveyance out of the mine by a continuous haulage system.

It is another object of the present invention to provide an extensive mining conveyor apparatus and method capable of rapid, efficient, and flexible extendable and retractable construction in a mine.

It is another object of the present invention to provide an extensible conveyor apparatus and method for providing a continuous conveyor belt for carrying coal or ore discharged from a continuous miner.

It is a further object of the present invention to provide an extensible conveyor apparatus having a holding frame capable of rapid, efficient, and flexible construction and disassembly in the confining spaces and constraints of an underground mine.

It is a further object of the present invention to provide an extensible conveyor apparatus which reduces the conveyor drive motor requirements in size and amperage and which permits for longer runs of conveyor between conveyor drive motors.

These and other objects of the present invention will become apparent from the detailed description which follows.

SUMMARY OF THE INVENTION

The present invention provides a conveyor apparatus including a middle roller on a roller-slider support piece for supporting a continuous conveyor belt, a side slider on each side of the middle roller on the roller-slider support piece, wherein each of the side sliders has a length less than the length of the middle roller, and substantially flexible connecting linkages positioned to connect the middle roller and the side slider. Substantially flexible connecting linkages are positioned to connect the side slider to a holding frame for holding the roller-slider support piece, including a pin for connecting the side slider to the holding frame in one of three apertures provided on the holding frame for receiving the pin. The three apertures are positioned on the holding frame to adjust and control the tracking angle at which the support piece receives the continuous conveyor belt. The slide slider having a length less than the length of the middle roller forms a troughing angle of 35 degrees or more. The connecting linkages are positioned to connect the middle roller and the side slider and are free to rotate with respect to a slider support bar and a roller shaft in the middle roller such that the roller-slider support piece and substantially flexible connecting linkages form a substantially catenary shape. The middle roller includes roller bearings and a series of sealing elements to prevent migration of abrasive and corrosive materials into contact with the roller bearings.

An extensible conveyor apparatus and method of the present invention for a continuous haulage system include a continuous conveyor belt for carrying coal or ore discharged from a continuous miner, a top roller-slider combination insert for supporting the coal-carrying or ore-carrying continuous conveyor belt, a bottom belt return, and a holding frame for holding the top roller-slider combination insert, wherein the holding frame is provided by a plurality of floor-supported frame members held in position by belt tension, the holding frame being capable of rapid and efficient extendable, retractable construction in the mine, and wherein substantially flexible connecting linkages are positioned to connect the middle roller and the side slider and to connect the side slider to a holding frame for holding the roller-slider support piece.

The present invention includes rails for connecting and holding adjacent frame members in position by press-fit attachment of the rails to the frame members. The rails preferably are quickly rotatable to change the top wearing surface.

The present invention provides a top roller-slider combination insert for supporting the mined-material-carrying continuous conveyor belt, the top roller-slider combination insert including a combination of rollers and sliders composed of a material which is lightweight, low friction, long wearing, flame-resistant, and quickly replaceable in an underground mine.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts the continuous mining operation in an underground mine by the room and pillar method and shows the tail piece and inboard or “inby” portion of the conveyor of the present invention.

FIG. 2 shows a perspective view of the novel conveyor apparatus and method of the present invention.

FIG. 3 shows a perspective view of the novel roller-slider combination conveyor insert of the present invention.

FIG. 4 shows a section taken along Section A—A of FIG. 2 of the novel conveyor apparatus and method of the present invention.

FIG. 5 shows a section taken along Section B—B of FIG. 2 of the novel conveyor apparatus and method of the present invention.

FIG. 6 shows a perspective view with partial cut-away of the novel roller-slider combination conveyor insert of the present invention.

FIG. 7 shows a perspective view, partially in section, of the novel roller-slider combination conveyor insert of the present invention.

DETAILED DESCRIPTION

Referring now to FIG. 1, continuous miner 10 is shown operating in position at the mine face 12 in a room and pillar method of mining. FIG. 1 depicts the continuous mining operation in an underground mine by the room and pillar method and shows the tail piece and inboard or inby portion of the conveyor of the present invention. Coal is mined at the mine face 12 to form rooms with pillars 13 of coal remaining for support. Continuous miner 10 is operated to remove most of the vertical coal or ore from the seam and to leave just a very thin top and bottom layer of coal or ore behind. In this manner, the mined material is not contaminated with rock or other materials found vertically just adjacent to and outside a coal seam.

Continuous miner 10 removes material from the face 12 and transports and passes the material along bridges 16 and 17 to conveyor apparatus 20. Conveyor apparatus 20 has tail piece 21 and side rails 22 and 24. Coal from the continuous miner is typically passed along bridges 16 and 17 to be discharged onto conveyor 20. Conveyor 20 carries the mined material to a main conveyor (not shown) for carrying the mined material out of the mine.

FIG. 2 shows a perspective view of the novel conveyor apparatus and method of the present invention. Referring now to FIG. 2, conveyor 20 includes side rails 22 and 24 interconnected with holding frame 26 for holding top roller-slider 27 and bottom belt return support 29. Holding frames 26 are floor-supported frame members.

Rails 22 and 24 slide onto pins attached to holding frame 26 as indicated by pins 28 for connecting rail 22 as shown in FIG. 2. Rail continuity insert 23 is positioned between ends of rail 22 to provide and maintain a continuity in the rail top surface for wheels (not shown) of a mobile bridge or other dolly or carriage to run on the top side of rail 22 or 24.

The rails 22 and 24 are provided with equal angular sides and side dimensions so that rails 22 and 24 can be rotated such that the wearing caused by the carriage or trolley operating on the top surface thereof can be shared by the other surfaces of the rails 22 and 24. By way of example, the rails can be round or square. In the case when rails 22 and 24 are square and provided with equal angular sides and side dimensions so that rails 22 and 24 can be rotated such that the wearing caused by the carriage or trolley operating on the top surface thereof can be shared by the other surfaces of the rails 22 and 24, an alignment brace 30 is provided to align the rail surfaces. Alignment brace 30 also provides higher rigidity to holding frame 26 and facilitates the prevention of snaking of the extensible conveyor system of the present invention.

FIG. 3 shows a perspective view of the roller-slider combination insert for the novel conveyor apparatus and method of the present invention.

Referring now to FIG. 3, roller-slider combination insert 27 has sliders 31 and 33 positioned on either ends of roller-slider combination insert support 27. Roller 35 is held on connecting link assemblies 41 bolting together sliders 31 and 33 onto roller 35. Holding frame connecting flanges 25 are welded onto the bottom frame 32 and bottom frame 34 of sliders 31 and 33, respectively, for connecting roller-slider combination insert support 27 to holding frame 26.

Slider 33 is shown held in channel 34 a welded to slider bottom frame 34. Channels 32 a and 34 a provide for a quickly replaceable feature of slider 31 or 33 without changing the entire roller-slider combination conveyor support piece 27.

The roller-slider combination insert in the extensible haulage system of the present invention allows the mine operator to use motors and conveyor drive devices having significantly less power. The slider-roller combination insert reduces the conveyor drive motor requirements in size and amperage. The slider-roller combination insert also permits for longer runs of conveyor between conveyor drive motors.

The roller-slider combination insert in the extensible haulage system of the present invention allows the mine operator to maximize capacity of an existing conveyor bottom structure without increasing conveyor width, thereby to use higher capacity conveyors without infringing on their clearance with the mine walls and to convey more massive amounts of mined material. Maintaining width is critical to stay within the fixed dimensions of the mine.

FIG. 4 shows the novel mining conveyor apparatus as viewed along Section A—A of FIG. 2.

Referring now to FIG. 4, top roller-slider 27 is shown having a substantially horizontally disposed middle section roller 35 and upwardly turned end section sliders 31 and 33 to form a troughing or cupping angle greater than about 35° of troughing/cupping and, preferably, greater than about 37°. Most preferably, horizontally disposed middle section roller 35 and upwardly turned end section sliders 31 and 33 form a troughing or cupping angle greater than about 37°.

Side rails 22 and 24 on opposite sides of the conveyor frame apparatus are shown having substantially equal angular sides and side dimensions so that the rails can be rotated to change the top surface as will be described in detail herein below.

Bottom belt return support 29 preferably of a lightweight abrasion-resistant material supports the belt return for the endless belt conveyor system.

The wearing surface of top roller-slider 27 can be replaced in the mine by removing top roller-slider 27. A new lightweight top roller-slider insert 27A can be fitted into and fastened into position by suitable fastener for connecting holding frame connecting flanges 25 to holding frame 26 to install the new top roller-slider 27 quickly in place in the mine.

It is not always necessary to remove the whole cross piece 27. Side sliders 31 or 33 may be replaced be a new side slider without removing cross piece 27 from the bottom structure. The top roller-slider 27 is formed such that it can be installed with any side slider 31 or 33 on either of the holding stands 26. The top roller-slider 27 thereby is interchangeable without regard to which side must be installed on a particular side of the holding support stand.

Top roller-slider 27A is shown as it is to be built into the holding frame 26. After top roller-slider 27A is positioned into holding frame 26 on either side of the top roller-slider, a simple cotter pin or the like is all that is needed to hold the top roller-slider 27 in position.

FIG. 5 shows a section taken along Section B—B of FIG. 2 of the novel conveyor apparatus and method of the present invention.

Referring now to FIG. 5, a section B—B taken from FIG. 2 is shown. Side rail 22 is shown to be press fit onto male connecting pin 28 adapted to be affixed to or to be a part of holding frame 26. Rail 22 is press fit onto pin 28, and the structure is held together by belt tension of the endless conveyor belt.

Side rails 22 are adapted to be capable of carrying a mobile bridge. The wheels (not shown) of the mobile bridge or other dolly or carriage would run on the top side of rail 22 or 24. The rails 22 and 24 are provided with equal angular sides and side dimensions so that rails 22 and 24 can be rotated such that the wearing caused by the carriage or trolley operating on the top surface thereof can be shared by the other surfaces of the rails 22 and 24.

The novel mining conveyor apparatus and method of the present invention incorporate side rails 22 and 24 which are press fit in attachment to the holding frames 26. In a preferred embodiment, the novel mining conveyor apparatus and method of the present invention incorporate a press fit attachment to provide a bolt-free attachment of side rails 22 and 24 to frame stand 26. The floor-mounted belt stand preferably is rigidly connected bolt-free to an adjacent floor-mounted belt stand.

Referring now to FIG. 6, novel roller-slider combination conveyor insert of the present invention is shown in perspective view with partial cut-away of roller 35.

The roller-slider combination conveyor insert of the present invention incorporates a catenary roller-slider insert consisting of two outer sliders 31 (and 33, not shown in FIG. 6) inclined at an angle, e.g., such as 37 degrees, from horizontal, and one large-diameter central roller 35 which is substantially horizontally oriented. Each slider 31 and 33 is supported by structural members 32 and 34 which can be provided by channel, bar, and plate. Support member 25 includes a vertically-oriented pin 36 which is insertable into one of the three holes 37, 38, or 39 in the top flange 40 of floor-supported holding frame 26.

Referring now to FIG. 7, the novel roller-slider combination conveyor insert of the present invention is shown in perspective view, partially in section. The large-diameter central roller 35 is free to rotate about central shaft member 42 but is not permitted to slide along the shaft 42. The slider support bars 32 (and 34, not shown in FIG. 7) are connected to the roller shaft 42 by means of connecting link assembly 41 having connecting links 44, bolts 46, and lock nuts 48. The bolts 46 go through holes in the connecting links 44, support bars 32 (34) and roller shaft 42. The connecting links 44 are free to rotate with respect to the slider support bars 32 (34) and the roller shaft 35 because the lock nuts 46 are not tightened fully, and a small amount of clearance is provided to permit free rotation of the connecting links 44 with respect to the support bars 32 (34) and roller shaft 35.

The insert assembly 27 (FIG. 6) comprising slider assemblies 31/32 (slider 31)/(slider support 32) and 33/34 (slider 33)/(slider support 34), connecting link assemblies 41, and roller assembly 35 is mounted onto the holding frame by means of pins 36. The entire assembly is free to assume a roughly catenary shape because the bolts 44 and pins 36 provide pivot points about which the components of the insert assembly 27 can rotate under the influence of their own weight and the weight of the coal being conveyed. The relatively steep angle of the sliders reduces horizontal shear loading of the pins 36 which in turn reduces stress and wear on the pins 36 and the supporting structure 26. Moreover, the relatively deep trough, which results, increases the coal-carrying capacity of the conveyor apparatus of the present invention.

Free rotation of the central roller 35 is essential so that only a small amount of torque is transmitted from the roller 35 to the shaft member 42. This, in turn, reduces the torque transmitted to the connecting link 44 and slider assemblies 31/32 and 33/34. Since the pins 36 and bolts 46 act to prevent rotation of the sliders 31 and 33, free rotation of the central roller 35 reduces stress and wear on these components.

FIG. 7 illustrates that the design of the central roller 35 effectively prevents migration of abrasive and corrosive materials into the tapered roller bearings 52 so that free rotation of the roller 35 around the shaft 42 is maintained despite the presence of these contaminants. This is accomplished by a series of sealing elements 50. A first umbrella-shaped seal of sealing elements assembly 50 keeps out the larger particles. A second seal fits tightly around shaft 42 and inside tube 54. This second seal excludes small particles and liquids from the bearings.

The third seal is an assembly of five elements. The first element is a cylinder with an outward-facing flange. Its inner diameter fits snugly over the shaft with the flange oriented against a bearing retaining ring. A second element is a felt ring which fits over and rests against the flange of the first element. A third element is a disk having a central hole which fits tightly over the first element and whose outer diameter is roughly equal to the outer diameter of the felt ring. This third element rests against the felt ring. A fourth element is a second felt ring which fits over the first element and against the disk. A fifth element is a second cylinder with an inward-facing flange. Its outer diameter fits snugly inside tube 52 and around the outer diameters of the first three sealing members. Its inward-facing flange rests against the second felt ring and its innermost diameter fits tightly over the small end of the first sealing member. Together, the five sealing elements of sealing elements assembly 50 serve to exclude all manner of contaminants to a high degree.

All of the sealing members except for the felt rings are made of a tough, corrosion-proof abrasion-resistant material. A cavity located between the third seal assembly and the tapered roller bearing is packed with waterproof grease. Both ends of the central roller 35 are equipped with a tapered roller bearing 52 and seals 50 as described above.

Axial movement of the shaft 42 relative to tube 54 is prevented by the tapered roller bearings 52, retaining rings, the stepped inner diameter of tube 54 or another snap ring and interference fits between the bearings, shaft 42 and tube 54. Axial movement of the roller body 35 relative to shaft 42 is prevented by the retaining rings and a heavy interference fit between these two parts.

The roller body is made of a tough, corrosion-proof abrasion-resistant material and a large outer diameter, e.g., such as by way of example, 4 inches outside diameter, serves to reduce its rotational velocity. The low rotational speed reduces the wear and tear on the roller and increases the maintenance interval correspondingly.

In one aspect, the conveyor apparatus and method of the present invention preferably provides a middle roller 35 having a four inches outside diameter (4″ O.D.), inside ball bearings, and connection to two side sliders 31 and 33 shorter than the middle roller 35 length. The preferred embodiment includes a deep troughing or cupping angle, e.g., of about 35 degrees, or more. The conveyor apparatus and method of the present invention preferably provides a roller-slider combination conveyor insert configured in a catenary fashion, similar to the all rollers drawings you have.

In one aspect, the conveyor apparatus and method of the present invention preferably provides the support frame top with three (3) holes for the insert pin from the novel roller-slider combination conveyor insert cross piece, as opposed to only one such pin hole, so as to adjust the tracking angle at which the cross piece faces when it receives the conveyor belt. The controllable tracking angle provides an ability to align to 90 degrees, so the moving conveyor is not biasing against the cross piece at an angle other than about perpendicular.

In one aspect, the conveyor apparatus and method of the present invention preferably provides a heavier bottom structural stiffener piece to the side sliders, e.g., support 32 for slider 31 and support 34 for slider 33. In this configuration, it has been found that the novel conveyor apparatus and method of the present invention are capable of receiving and handling heavier loads and further provide for a secure attachment to the middle roller.

In one aspect, the conveyor apparatus and method of the present invention preferably provide side frame stands 26 which are higher to accommodate the deeper cupping or troughing angle of 35 degrees or more. In this manner, the width of the conveyor structure may be maintained, e.g., at 36 inches.

The novel mining conveyor apparatus and method of the present invention provide quick and significantly efficient extendible and retractable construction of the belt stands in the mine to facilitate room advancement. As the continuous miner extends into the face, the novel mining conveyor and method of the present invention can extend with it.

The conveyor apparatus of the present invention can provide standard conveyor widths of 30 inches, 36 inches, or 42 inches, or other widths, e.g., non-standard widths, as required in a particular application. The larger widths are used for more massive amounts of coal to be conveyed, e.g., coal sheered from a long wall miner. For larger conveyor widths, e.g., the 42 inches wide conveyor, rollers can be added. An optional idler roller can be installed or substituted for a slider as part of the conveyor so that the capacity and/or length of the conveyor can be increased.

Also for larger conveyor widths, e.g., the 42 inches wide conveyor, box tubing preferably is used in place of a beam for the roller-slider combination insert side sliders supports 32 and 34 to provide more strength. It has been found that a 2 inches square box tubing works well for a 36 inches wide conveyor, and a 2½ inches square box tubing works well for a 42 inches wide conveyor. We have found that the 2½ inches square box tubing provides double the strength of the 2 inches square box tubing, e.g., 1.1 kip (1,100 load capacity) for the 2 inches square box tubing compared to 2.1 kip (2,100 load capacity) for the 2½ inches square box tubing.

We have found that the larger box tubing also works well for the larger bridges more frequently being used today behind the continuous miners.

The conveyor length in the extensible continuous haulage system of the present invention can be 750 feet to 1,000 feet or longer and will be limited only by mining regulations.

The floor-mounted holding frames are positioned to be interconnected with press-fit attachment of side rails to the frame members. No bolts are needed. The novel mining conveyor and apparatus of the present invention provide a superior advantage over conventional conveyor apparatus in that bolts are eliminated. Workers who have toiled in the dark, confined spaces and constraints, often times working in muck and mire, will appreciate the feature of eliminating these bolts. Bolts typically are lost, dropped, or at least are difficult to thread and bolt up. Moreover, bolts become gunked up in the muck and mire in a mine. The gunked-up bolts are difficult to thread or install. Not only is it easier physically to build and disassemble the novel conveyor of the present invention, but also these bolts are eliminated for a substantial cost savings because these bolts are not cheap, but rather have a material cost on the order of about three dollars each to replace (1997 dollars) irrespective of the labor intensive cost of installation.

The novel mining conveyor and apparatus of the present invention provide an extensible conveyor apparatus for a continuous haulage system including a continuous conveyor belt for carrying coal or ore discharged from a continuous miner, a top roller-slider having flexible mechanical connecting linkages, for supporting the coal-carrying or ore-carrying continuous conveyor belt, a bottom belt return, and a holding frame for holding the top roller-slider.

The holding frame is provided by a plurality of floor-supported frame members held in position by belt tension, the holding frame being capable of rapid, efficient, and flexible extendable, retractable construction in the mine. The conveyor belt itself holds the floor-mounted holding structure together in tension. The conveyor belt is held taut by jack belt tensioning, and the belt tension on the floor-mounted holding frame.

The top roller-slider preferably is provided by a combination of rollers and sliders composed of a material having a low coefficient of friction, e.g., such as a coefficient of friction less than about 0.4. Further, the top roller-slider combination is comprised of a material having high abrasion resistance. The top roller-slider combination also preferably is composed of a material having a low flammability acceptable to and approved by the U. S. Mine Safety and Health Administration for service in a mine. Such a material to satisfy these requirements is provided by a material composed of ultra high molecular weight polyethylene available commercially, e.g., such as from the Poly-Hi Solidur Plastics Company of Delmont, Penn.

The conveyor belt and frame combination of the present invention can be designed to provide a low profile continuous haulage system for carrying coal from low coal seams, e.g., such as less than about 48 inches in vertical height. The low coal seams make it extremely difficult for physical activity in the confining spaces and constraints of the underground mine. Every physical effort is magnified many fold in difficulty level by the confining spaces of the low coal.

The side rails, e.g., side rails 22 and 24 as shown in the drawings, are provided by lightweight rails. In one embodiment, the lightweight rails are provided by round or square tubular steel material and weigh less than about five pounds per foot and preferably less than about four pounds per foot, e.g., such as less than about 25 pounds, preferably less than 20 pounds, over about five feet of length. The lightweight rails of the present invention are compared to rails weighing as much as 100 to 150 pounds and more over about five feet of length in conventional conveyor systems.

The lightweight rails are adapted to be placed into press-fit attachment with protruding pins horizontally fixed to the holding frame members. In this way, the side rails include tubular rails acting as pin-receiving connecting members for receiving the protruding pins horizontally fixed on the frame members. The four-sided tubular rails can be quickly rotated to change the top wear surface and extend the service life of the rails for carrying the mobile bridges of the continuous haulage system of the present invention.

The top roller-slider can be formed preferably by a lightweight replaceable roller-slider insert composed of the material described herein above. The roller-slider combination insert can be formed to weigh less than about twenty-five (25) pounds for a thirty-six (36) inch roller-slider insert, preferably less than about twenty (20) pounds, and is quickly interchangeable in the mine. The reduced weight is about half that of conventional steel rollers.

In the conveyor system of the present invention, the conveyor belt itself holds the floor-mounted holding structure together in tension. The conveyor belt is held taut by jack belt tensioning and the belt tension on the floor-mounted holding frame. In one aspect of a preferred embodiment of the extensible continuous haulage system of the present invention, side rail 22 is shown to be press fit onto male connecting pin 28 adapted to be affixed to or to be a part of holding frame 26. Rail 22 is press fit onto pin 28, and the structure is held together by belt tension of the endless conveyor belt.

The importance of the structure held together by belt tension of the endless conveyor belt in the extensible continuous haulage system of the present invention is highlighted by side rails 22 capable of carrying a mobile bridge. The wheels of the mobile bridge or other dolly or carriage run on the top side of rail 22 or 24.

The importance of the structure held together by belt tension of the endless conveyor belt in the extensible continuous haulage system of the present invention is further highlighted by side rails 22 and 24 provided with equal angular sides and side dimensions so that rails 22 and 24 can be rotated such that the wearing caused by the carriage or trolley operating on the top surface thereof can be shared by the other surfaces of the rails 22 and 24. The extensible continuous haulage system of the present invention provides rails for connecting and holding adjacent frame members in position by press-fit attachment of the rails to the frame members, wherein the rails are quickly rotatable to change the top wear surface.

The elements of the extensible continuous haulage system of the present invention provide an extensible conveyor apparatus for a continuous haulage system which can operate or perform effectively and efficiently in a continuous haulage system. Conventional conveyors do not work with continuous haulage systems or run continuous haulage because their conveyors do not form a track needed for the mobile bridge units extending from and attached to the continuous mining machine to tram or travel on to form the continuous haulage system.

The conveyor system of the present invention provides a holding frame for holding the top slider capable of rapid, efficient, and flexible extendable, retractable construction in the mine.

The quick interchangeability (in the mine) feature of the present invention eliminates the need to handle, remove, and reinstall stainless steel roller-sliders which typically weigh up to ten times heavier than the roller-slider of the present invention. The stainless steel slider must be removed to a fabrication shop located outside the mine where the stainless steel is welded into place on the frame members as is required in conventional conveyor systems. The roller-slider insert of the present invention, however, can be rebuilt and retrofitted to provide quick interchangeability directly in the mine.

The top roller-slider is formed such that it can be installed with either side slider, 31 or 33, adjacent either of the holding stands. The top roller-slider thereby is interchangeable without regard to which side must be installed on a particular side of the holding support stand.

The novel mining conveyor apparatus and method of the present invention are capable of providing a low profile, lightweight, continuous conveyor apparatus which is quickly extendable, retractable, and moveable in a low seam coal mine for continuous haulage room advancement. The present invention includes a continuous belt, a top roller-slider of a plastic roller-slider insert weighing less than about twenty-five (25) pounds for a thirty-six (36) inch roller slider insert, preferably less than about twenty (20) pounds, and composed of a material having a low coefficient of friction, high abrasion resistance, low flammability, and capable of supporting the continuous belt as it carries coal from the discharge of a continuous miner and for forming a troughing or cupping angle greater than about 25 degrees, preferably greater than about 35 degrees for larger volumes of material to be conveyed. In one aspect, the present invention further includes a floor-mounted holding stand less than about fourteen inches in overall vertical height for holding said top roller-slider and a bottom roller-slider belt return in position such that the holding stand is capable of and provides quick and efficient extendable or retractable construction in the low seam coal mine to facilitate rapid room advancement at a minimum of continuous miner production downtime.

In one aspect, the present invention includes lightweight rails which can be designed to weigh less than about five pounds per foot, preferably less than about four pounds per foot, of length interconnecting the holding stand without bolts, the rails being capable of carrying a mobile bridge of the continuous miner. The lightweight rails further are quickly rotatable in the low seam coal mine to change wear surfaces on the rail to extend the life of the bridge-carrying rail.

We have found that the conveyor apparatus and method of the present invention permit a mining crew to “belt-up” in as short a time as twenty (20) minutes, for example. This short time is virtually unheard of in mining operations today, particularly in low seam coal mining. This quick extensible capability permits a crew to “belt-up” as many as two and three times per shift, if needed. It has been found that, upon an inspection and analysis of production log sheets for a particular shift or production period, the mining operation can be conducted without an apparent downtime for extending or retracting the novel extensible continuous haulage apparatus of the present invention.

We have found empirically that the roller-slider combination insert in the extensible haulage system of the present invention allows the mine operator to use motors and conveyor drive devices having significantly less power. The slider-roller combination insert reduces the conveyor drive motor requirements in size and amperage. The slider-roller combination insert also permits for longer runs of conveyor between conveyor drive motors.

We also have found that the roller-slider combination insert in the extensible haulage system of the present invention allows the mine operator to use larger conveyors and heavier belts, thereby to convey more massive amounts of mined material.

The novel conveyor apparatus and method of the present invention accordingly are significantly superior over conventional conveyor apparatus and methods which typically result in significantly less production during a shift in which the conveyor must be extended or retracted.

The apparatus and method of the present invention are not intended to be limited to the descriptions of specific embodiments herein above, but rather the apparatus and method of the present invention should be viewed in terms of the claims which follow and equivalents thereof. 

What is claimed is:
 1. A conveyor apparatus, comprising: a. a middle roller on a roller-slider support piece for supporting a continuous conveyor belt; b. a side slider on each side of said middle roller on said roller-slider support piece, wherein each said slide slider has a length less than the length of said middle roller; and c. substantially flexible connecting linkages positioned to connect said middle roller and said side slider.
 2. A conveyor apparatus as set forth in claim 1, further comprising; d. a connecting linkage positioned to connect said side slider to a holding frame for holding said roller-slider support piece.
 3. A conveyor apparatus as set forth in claim 2, wherein said holding frame comprises a plurality of floor-supported frame members held in position by belt tension and rails for connecting and holding adjacent frame members in position by press-fit attachment of said rails to said frame members.
 4. A conveyor apparatus as set forth in claim 2, wherein said connecting linkage positioned to connect said side slider to a holding frame for holding said roller-slider support piece comprises a pin for connecting said side slider to said holding frame in one of three apertures provided on said holding frame for receiving said pin.
 5. A conveyor apparatus as set forth in claim 4, wherein said three apertures are positioned on said holding frame to adjust and control the tracking angle at which said support piece receives said continuous conveyor belt.
 6. A conveyor apparatus as set forth in claim 5, wherein said slide slider having a length less than the length of said middle roller forms a troughing angle of 35 degrees or more.
 7. A conveyor apparatus as set forth in claim 6, wherein said connecting linkages positioned to connect said middle roller and said side slider are free to rotate with respect to a slider support bar and a roller shaft in said middle roller such that said roller-slider support piece and substantially flexible connecting linkages form a substantially catenary shape.
 8. A conveyor apparatus as set forth in claim 7, wherein said side slider having a length less than the length of said middle roller forms a troughing angle of about 37 degrees.
 9. A conveyor apparatus as set forth in claim 7, wherein said middle roller comprises roller bearings and a series of sealing elements to prevent migration of abrasive and corrosive materials into contact with said roller bearings.
 10. A conveyor apparatus, comprising: a. a middle roller on a roller-slider support piece for supporting a continuous conveyor belt; b. a side slider on each side of said middle roller on said roller-slider support piece; c. substantially flexible connecting linkages positioned to connect said middle roller and said side slider; d. a connecting linkage positioned to connect said side slider to a holding frame for holding said roller-slider support piece; e. rails for connecting and holding adjacent frame members in position by press-fit attachment of said rails to said frame members; f. pins attached to said holding frame for bolt-free press-fit attachment of said rails to said frame members; and g. a rail continuity insert positioned between rail ends to provide and maintain a continuity in the rail top surface for wheels of a mobile bridge or other dolly or carriage to run on the top side of said rails, wherein said rails are rotatable to change the top wear surface.
 11. A conveyor apparatus as set forth in claim 10, further comprising: h. an alignment brace for aligning the rail surfaces.
 12. A conveyor apparatus as set forth in claim 11, wherein said rails comprise round or square tubular rails acting as pin-receiving connecting members for receiving said pins protruding horizontally fixed on said frame members.
 13. A conveyor apparatus as set forth in claim 12, wherein said roller-slider support piece provides a large angle of troughing/cupping greater than about 35 degrees of troughing/cupping in said coal-carrying continuous conveyor belt.
 14. A conveyor apparatus as set forth in claim 13, wherein said roller-slider support piece has a low coefficient of friction.
 15. A method of continuously hauling coal or ore in a mine, comprising: a. receiving mined material from a continuous miner in an underground mine; b. conveying said mined material on a continuous belt; c. supporting said continuous belt by a floor-mounted belt stand rigidly connected bolt-free to an adjacent floor-mounted belt stand and held by tension of said continuous belt on said stands; d. providing a roller-slider combination means for supporting said continuous belt; e. providing substantially flexible connecting linkages between a middle roller and side sliders on said roller-slider combination means; and f. providing longitudinal rails for connecting said belt stands in position to form a holding frame capable of quick and flexible extendable and retractable construction in the mine, wherein said rails are adapted to carry a wheeled-frame continuous haulage bridge vehicle riding on said rails.
 16. A method as set forth in claim 15, further comprising providing a rotatable configuration in said rails to relieve the top wear surface. 